Complete suckage

jacketfan89 · 10-14-2009, 04:59 PM

OK. I ALMOST just beat the hell out of my Porsche with a 1/2" drive torque wrench...I got the starter and slave mounted and everything hooked up and said "alright now lets make sure this thing starts."

Now, I was already worried that I wouln't get a start out of it. Here's THAT story. So yesterday, (as I read clarks garage) I adjusted the sensor FURTHEST from the firewall with the .8 mm washer to the FLYWHEEL (which is what Clarks-Garage said to do.)

So I made my post about whether or not I could start it once I get my starter back on, and while waiting on a reply I went ahead and put the pressure plate and clutch disk on. WELL, which I was torquing the PP bolts (the first time) I noticed that the assembly wasn't turning as it had when I removed them. I didn't think anything of it.

So I go and check for replies and of course within 30 minutes I have one..........

I was supposed to adjust the sensor CLOSEST to the firewall to the PRESSURE PLATE. SOO I look up by the pressure plate and theres my sensor all dented and caught up in the starter ring. :-D

I took everything back off to make it easier to get to the bracket allen bolts, loosened the bolts and REINSTALLED the clutch disk and Pressure Plate so I could regap the sensor even though it was a little dented. (At this point it still wasn't too bad, but I did question whether or not it would even work.)

When I went to adjust the clearance again...Guess what?? Because I wasn't taking my time, I let my sensor get eaten by the starter ring AGAIN. At this point it was pretty badly bent (coming through the bracket at an angle) but I still was able to hit the bracket with the hammer and get the sensor loose. Well, I went ahead and gapped it with the washer to the PRESSURE PLATE, and was able to reinstall everything.

P.S I figured out the thing with my clutch fork. All is good now!

So I mounted my starter and my slave cylinder went under the hood to hook the sensors back up and there was no telling which receiving end was which as they had come out of their respective places.

I made an educated guess from the wiring and hooked the sensors up...attached the battery and got in the car.

Of course no start. So I thought eh probably just got the cable swapped, went back under the hood and as I tried to detach the sensor I DIDN'T replace (also of course the one that wasn't JUST bent) the plastic plug breaks off in the receiving end. Great.

So I have one completely bent sensor....one sensor with a broken end and clutch that is freshly put together that I'm going to have to take apart AGAIN!!!

This is absolutely frustrating. Not only that, I need two MORE reference sensors. and MAYBE a bracket depending upon whether or not I can get this bent dented mess out of the bracket.

If anyone has any good sensors removed, I need em. Hopefully thats all thats wrong. The car turns over but just won't start and I'm willing to bet its that damned bent sensor.

Thanks for the support,

Matt

Dave101 · 10-14-2009, 06:24 PM

I wish that i could help you. You are doing something that i have not had to do yet and from your write up I think I will only attempt it if it is absolutely necessary. i hope someone else here can figure it out.

speedracing944 · speedracing944's Garage

You should notch out your bellhousing where the sensors are so next time you can remove your bellhousing without disturbing your sensors. I wish you the best of luck. Just take your time and triple check your work. Don't get too frustrated as there are many things worse that could happen. Just take a deep breath.

Speedy

cvriv.charles · 10-14-2009, 09:18 PM

DUDE!!! Slow the F@#$ down. Your rushing. If your not sure. Post your question and walk away from the car. Wait till your question has been answered first. You'll do more harm to your car by rushing and guessing then taking your time and knowing. slow down.

Grandad#3 · 10-14-2009, 10:07 PM

Hi Jacket, You can buy just the connector end at 944online.com. That will keep you from having to buy a new sensor.

Cheers,
Larry

John_AZ · 10-15-2009, 04:43 AM

Matt,

I know you did cut the bell housing sensor area out. The purpose for this is to set the sensors with the bell housing off. The flywheel should have the reference "pins' at the bottom of the flywheel. Gap the sensors and then slide the bell housing on under the sensor bracket. It also makes a repeat clutch job easier because you do not have to worry about the sensors or bracket. Just make sure the FW pins point down.

GL
John_AZ

SolReaver · 10-16-2009, 09:17 PM

Yea, I ALMOST followed Clarks advice and did the 0.8mm washer thing. Yea. Clarks is a pretty good reference. However, they kinda dropped the ball on that one IMHO. I gapped the sensors with feeler gages from underneath after notching the bell housing. It took a bit of doing and was not a hec of a lot of fun. I would suggest gluing a Plastic or paper piece about the right thickness to the bottom of the sensor and then just adjust the thing till it makes contact and leave it there.... If the spacer gets chewed up or falls off...so what??. Do the notch on the housing if you haven't already and set the gap some other way than the Bass Akward method that Clarks recommends. The connectors are made out of a special plastic that was scientifically formulated to disintegrate with age and both ends should be replaced with anything that will form a good connection. Pick up something at the junkyard or parts store and soldier the new connectors to the old wiring. As for the sensors themselves...post a pic and lets see how bad ya bashed them. They can take some abuse but it is not a good idea. Scratches on the case are OK, but mushrooming and deformation are not a good sign. I think there is some cross match to bmw sensors or something if you need to replace em.

These cars can be VERY frustrating to work on. I have had neighbors wonder why I was screaming in my garage during the Fuel Injection incident. As with many things...Walking away when the rage builds within is the best idea.

jacketfan89 · 10-17-2009, 06:18 AM

You guys have been most helpful....let's just say that the sensor is SO bent and dented that I can't even get it out of the bracket lol.

I have two sensors on their way...I'm hoping that I can salvage my old (new) bracket.

Lol the sensor basically was stuck in the starter ring teeth WHILE I torqued the pp bolts and it was in there so tight the whole assembly wouldn't even turn...

Tomorrow I'm going to take the bellhousing back off and see if I can get the bracket off without removing the PP AGAIN...it should be easy.

I'm just hoping that after I replace the sensor the damn thing cranks...if not I messed something else up lol.

SolReaver · 10-17-2009, 08:00 AM

hmmm...I usually leave the sensor block unattached until after the FW and PP are installed. Installing and gapping the sensors is the last step before the bell housing goes back on. Remember to tilt the engine to get room for the bell housing to go on. (assuming the BH is notched) The sensor block is known to Slip out of adjustment later on so be sure to clean all the threads and use the appropriate thread locker. IMHO, use something that takes a while to cure as the adjustment process may take some time. I wound up painting over the bolts when finished. Careful about confusing the Speed and ref sensors, It is really easy to do. (ask me how I know). Figure a few good hours on this task alone, but once you have it done. It is done for good.

jacketfan89 · 10-17-2009, 09:23 AM

Lol...if you switch them and start the car does it mess them up or can you simply just switch the wires?

Techno Duck · Techno Duck's Garage

No damage done swapping the connectors, the car will just not start.